Verification of a CAE extrusion simulation package with an actual profile extrusion die

The determination of die dimensions for profile extrusion has largely been based on a method of ''trial and error'' by experienced individuals in the field. Part of the difficulty in determining die dimensions by trial and error is anticipating how die swell, volumetric shrinkage, varying velocity, and underdraft (draw down), will effect the extrudate emerging from the die [1]. This method becomes even more complicated when variations in wall thickness and geometry are desired. Overall, trying to define flow geometry intuitively is prone to error and usually results in numerous modifications to the die. To help predict die dimensions and flow properties more efficiently, a computer aided engineering (CAE) extrusion simulation package, Polyflow, has been developed. The intent of this paper is to verify the ability of the CAE package to predict extrudate geometry. Once a prediction of the profile geometry has been made by the CAE software, it will be compared against the actual extruded part dimensions currently being manufactured.